Documentation

Startup of a synchronous non-SEW motor

Setting the motor encoder

(see section 3)

Version: 2.1

Contents

1 General Information............................................................ 2
1.1 Preparations ................................................................................................................ 2

2 Initial startup ....................................................................... 3

2.1 Motor parameters ........................................................................................................ 5
2.2 System parameters ..................................................................................................... 6
2.3 Save and download..................................................................................................... 7
2.4 Current controller........................................................................................................ 8

3 Adjustment of the motor encoder ..................................... 9

3.1 Description of the functions ...................................................................................... 9
3.2 Starting the interface ................................................................................................ 10
3.3 Resolver ..................................................................................................................... 13
3.4 HIPERFACE® encoder............................................................................................... 16
3.5 Calibration error ........................................................................................................ 19

4 Startup of the speed controller ....................................... 20

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1 General Information
This document describes the general startup of a synchronous non-SEW motor with a
MOVIDRIVE® unit. This special software can be used with the following units:

Unit Encoder
MDS60A Resolver
MCH40/41/42A HIPERFACE®
MDX61B DEH11B (HIPERFACE®) or DER11B (resolver) option card

1.1 Preparations
- Check that the U, V and W phases have been connected properly in accordance with the
regulations.

- Connect the encoder according to the installation instructions. Check correct connection in the
“Process values” window of MOVITOOLS® Shell by checking speed and actual position values. If
you turn the rotor clockwise (as viewed from front onto the motor shaft), the speed must be a
positive value and the actual position will increase in value (4,096 pulses per revolution).

If this is not the case, swap sin+ with cos+ and sin- with cos-.

If the encoder is a resolver:

- The transmission ratio must be approximately 0.5. A smaller value reduces the ratio between
signal and fault resulting in greater position, speed and torque problems that can ultimately trigger
an encoder error. A larger value will approach the evaluation limits also triggering an encoder
error.

- The resolver must have two poles (a pole pair).

- If you do not have a wiring diagram for the resolver, you can connect it using the following
illustration (connection will most likely be to the unit (X15)).

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See the MOVIDRIVE® manual for additional information on how to connect an encoder to the
inverter.

Note
The maximum length for the encoder cable quoted in the MOVIDRIVE® manual will be different if
you are using an encoder that does not meet SEW specifications. The length of this cable
determines the suitability of the encoder.

2 Initial startup
Proceed as follows to start the special program “MTFMotor.exe” for startup of non-SEW motors:

We recommend standard startup in Shell with any synchronous motor (e.g. DFY56M) to set other
parameters, such as speed ramp, setpoint source, temperature protection, etc. Set the operating
mode to speed control.

Press the Shift key and double-click on any gray field. Select “MTFMotor.exe.”

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The following window appears:

Select “Startup of a non-Sew synchronous motor” to enter motor data.

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2.1 Motor parameters
Enter all motor parameters.

Motor signature:
Enter the motor signature on the nameplate. For information purposes only.

Motor rated current:

Rated current stated on nameplate

Max. motor current:

The first time, set the maximum motor current to the motor rated current. This means the output
current for setting the current controller and adjusting the encoder is limited to the rated current.

Motor rated speed:

Maximum speed stated on nameplate. If startup is to be performed on the A unit, this value is
limited to 5,500 rpm; it is 6,000 rpm for B units.

Motor rated torque:

Rated torque stated on nameplate

Number of pole pairs:

Number of motor pole pairs

Phase inductance:
Enter the inductance of a phase. You need the inductance for the calculation of the current
controller. If you do not know the value, enter a small, approximate value of a similar motor. You
can alter this value later when adapting the current controller.

Resolver offset:
In most cases the resolver offset will be an unknown value. The drive must be enabled to adjust
the current controller at a later date. However, the resolver offset must be set to the correct value
to ensure trouble-free operation of the motor. Therefore, start by entering the standard SEW value
(resolver offset = 270° / number of pole pairs). This value will be effective for a resolver and a
HIPERFACE® acting as encoder. Section 3 (Adjustment of the motor encoder) describes how to
determine this value.

Mains rated voltage:

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Enter the voltage that is used to power the inverter.

Output rated current:

In online mode, you will see the rated current of the connected inverter. You can alter this value in
offline mode to calculate the controller parameters.

2.2 System parameters

Click on “Next” and enter the parameters for the speed controller (e.g. stiffness = 1, drives with
gear unit always “without backlash”).

Stiffness:
Enter the stiffness of the speed controller. Stiffness is a measure for the velocity of the speed
control loop. The value can range from 0.5 to 2. The standard setting is 1. Increasing the stiffness
causes the control speed to increase. The control loop will start oscillating from a critical value. The
control response is slower when the stiffness is reduced. The lag fault increases.

Drive:
Select the mechanical situation of the drive train, i.e. with or without backlash.

Comparable SEW size:

If you are not familiar with the moment of inertia for the motor, enter that of a similar SEW motor.
The respective value will be entered in the edit field.

Motor:
Enter the moment of inertia for the motor.

Load:
Enter the maximum external moment of inertia converted for the motor shaft. You also have the
option of determining the moment of inertia for the load automatically during a travel process
(relatively large speed range, motor and regenerative). Start the process by clicking on “Testing.”

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You can use the same process to estimate the moment of inertia for the motor. Enter 0 for the
motor moment of inertia and start the process. The motor moment of inertia will be displayed in the
load field and you can enter it in the correct field.

You can adapt these parameters to the application later in the “Startup of a speed controller”
window.

2.3 Save and download

Click “Next” to save the changes in a file for later use. Then continue with download.

This description is limited to those parameters that have a direct effect on the operation of a
synchronous motor. You will have to make the settings for speed ramps, setpoint source,
temperature protection, etc. in Shell.

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2.4 Current controller
The following window opens after download. You can now adjust the current controller. We
recommend the following procedure:
- Enable drive in speed control mode with a small speed setpoint ≠ 0
- Motor rotates at constant speed
- Increase P gain of current controller until you hear a high-frequency whistling noise.
- Click “Adapting” (value is halved and written to the inverter)
- Click “Accept” (resulting inductance is entered in the edit field on the first page)

The encoder settings are completely incorrect if the motor does not move after it has been enabled
or if it accelerates to a high speed (possibly causing an error). In this instance you will have to
change the resolver offset in the “Motor parameter” window, download the parameters once again
and restart operation. Continue to change the offset until the motor rotates at a constant speed.
This does not ensure that the encoder is set correctly but the current controller can be adjusted.
The following tips will help you determine suitable values for the resolver offset:
Motor with three pole pairs Æ 360° / 3 = 120° Æ one cycle is 120°. This means 90° (resolver offset
currently set) and 90° + 120° = 210° identical (only one cycle later) Æ Try again with an angle
between 90° and 210°, e.g. the median value 90° + 120° / 2 = 150° and so on.

Increase value until a high- Value is

pitched whistling is heard at halved
the motor

Inductance is entered in the edit

field on the first page
Note
The resolver offset is effective in units with a resolver as well as a HIPERFACE® encoder.

You have now set all controller parameters. If the encoder cannot be adjusted for the motor, you
can set the correct rotor angle in the next step. Click on “Basic menu” in the active window and
proceed as described in the next section.

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3 Adjustment of the motor encoder

3.1 Description of the functions

The absolute angle of the rotor to the stator is necessary for field orientation when operating
synchronous motors (DY/CM/CP and non-SEW motors) with MOVIDRIVE®. If this reference gets
lost due to certain circumstances (defective resolver, incorrect setting of HIPERFACE® encoder
due to brake replacement), the encoder position will have to be determined again.

You have two options to make this measurement. You can determine this position by using a
special encoder calibration device. If such a device is not available (e.g. at customer site), you can
activate the calibration function integrated in the firmware.

The calibration process will take place as follows:

1. Current injection and setting the angle to 0° causes the motor to come to a standstill at a certain
position.

2. The current position is determined within three seconds and a speed of less than 30 rpm
(~2 Inc/ms).

3. Move the drive by setting the angle by one revolution in a positive direction, then continue with
2. If the traveled distance is not 4,096 +/- 20Inc, an error flag (H3.1) will be set.

4. Move the drive back by one revolution, then continue with 2. If the traveled distance is not 4,096
+/- 20Inc, an error flag (H3.2) will be set.

5. If the distance traveled in positive direction deviates by 20Inc from the way back, then an
additional error flag (H3.3) will be set. You will reach an accuracy of

360°
⋅ 20 Inc ≈ 1,76°mech
4096 Inc

Calculate the installation angle (resolver) or motor position (HIPERFACE®) by averaging the last
two positions.

The following errors are determined by this process:

- Encoder signals reversed (incorrect counting direction)
- Blocking of drive
- Inaccuracies caused by friction (e.g. gear unit)

If you cannot detect a motor standstill at the measuring spots (e.g. through external influences), an
encoder error (F14 with suberror 8) will be triggered after approximately six seconds.

6. The entire control and status information takes place or is displayed via IPOS variables:

H0: Indicates installation angle in 0.1° increments mechanical

H1: Resolver: Indicates associated resolver offset (for index 8698)
HIPERFACE® encoder: Indicates new motor position in Inc
H2: Maximum injected current from 0% to 150% (MDx/MCx A) or 200% (MDx B) of the rated unit
current
H3 : Error or status information
Bit 0 = 1: Calibration process complete
Bit 1 = 1: Error during travel in positive direction
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 Bit 2 = 1: Error during travel back
Bit 3 = 1: Calculated angle inaccurate
H4: Indicates measuring error in 0.1° units electrical
H5: Angle currently set
H6: 1st measured position (H511)
H7: 2nd measured position (H511)
H8: 3rd measured position (H511)
H9: HIPERFACE® encoder only: Controlling the write process for the HIPERFACE® encoder
= 0: Deactivated
= 1: Value in H1 written to HIPERFACE® encoder
= 2: Write process finished
H10: 1st measured raw position (index 8782)
H11: 2nd measured raw position (index 8782)
H12: 3rd measured raw position (index 8782)

The drive can be run without any load or friction (e.g. gear unit) to increase accuracy. Any load or
friction (e.g. gear unit) will result in inaccuracies.
All configuration parameters are not protected against power failure, i.e. they are permanently
deleted after power off/on.

3.2 Starting the interface

A separate application is available is for adapting the motor encoder. Before starting the interface,
please read section 1.1. (Preparations). The interface can either be starting in the tool “Startup of
Non-SEW synchronous motors“ under “Adjustment of the motor encoder” or using the shift-double
click function in the Manager.

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This application automatically detects the use of a resolver or HIPERFACE® encoder. The
following window opens after start:

Approximately 2/3 of the

rated motor current

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Enter the calibration current in [A]. Enter about 2/3 of the motor rated current. If you receive an
error message after the measurement, increase the current and restart (assuming correct
connection). You can only perform the calibration process with parameter set 1.

Important: A high current can damage the motor if applied for an extended period of time!

After “Start,” you will have to reset the controller inhibit to enable the drive.

The following settings are made in the unit:

- Disconnection the of parameter lock (P803)

- Stop of IPOS program
- Deactivation of brake function (P730)
- Deactivation of calibration function
- H0 – H12 are deleted
- “No enable” is set
- Deactivation of brake function (P730)
- Deactivation of speed monitoring (P500)
- Deactivation of reverse direction of rotation (P350)
- P gain of current controller will be reduced to 70% of the original value
- Activation of the calibration function

These measures are “volatile,” i.e. they are stored in RAM only. All original settings will be restored
when the unit is turned off/on.

The 7-segment display now shows an “E” (MDx only) and the current angle is displayed as a
diagram. The rotor rotates one revolution clockwise, then one revolution counterclockwise.

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After successful measurement, there will be different messages depending on the encoder used.

3.3 Resolver

You have the choice of mechanical or electronic adjustment.

Angle for mech. adjustment

Offset for electron. adjustment

The first value is the mechanical angle of the resolver. By “activating” this function, the resolver
offset will be set depending on the number of pole pairs in the unit and the resolver on the motor
can be rotated until the value 0° is displayed in the edit field. Because the rotor is used as a
reference, you cannot set a controller inhibit during the adjustment process (power supply to motor
must continue, be careful when rotating the resolver). We recommend performing a mechanical
adjustment for SEW motors (when connecting motor to a different MOVIDRIVE®, it can be taken
into operation with a standard process).
Electronic adjustment is deactivated after mechanical adjustment.

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The second value is the calculated resolver offset. If you do not want to perform a mechanical
adjustment, you will have set this value with “Accept.” We recommend this process for non-SEW
synchronous motors.

The measuring error indicates by how many degrees (converted to electrical degrees) the travel is
different in positive and negative direction.

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An error during calibration can have several causes. You will find additional information in section
3.5.

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3.4 HIPERFACE® encoder

For units with HIPERFACE® options, you can either write the position into the encoder or make an
electronic adjustment using the “Resolver offset” parameter.

Note
Make sure to read the guidelines regarding limited warranty by the manufacturer when writing
values into the HIPERFACE® encoder.

The first value is the mechanical installation angle but you cannot manually rotate a HIPERFACE®
encoder on the motor. The value is for information purposes only. Perform the required adjustment
by pressing “Accept.”

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If you accept the encoder offset, the parameter “Resolver offset” will be written to the unit. We
recommend this process for non-SEW synchronous motors. There will be no adjustment in the
HIPERFACE® encoder.

If the new motor position is accepted, the firmware will write the position in the encoder.

At the same time, the resolver offset will be set to the standard value. As the rotor is used as a
reference, you cannot set a controller inhibit during the adjustment (power supply to motor must
continue). Encoder offset can no longer be accepted after this adjustment.

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An error during calibration can have several causes. You will find additional information in section
3.5.

If the adjustment of the motor encoder took place during startup of a non-SEW synchronous motor,
the measured resolver/encoder offset can be copied to the “Motor parameters” page. This is only
possible if mechanical adjustment of the resolver was not performed and the value was not written
in the HIPERFACE® encoder. This means the value can be set directly in case of a new startup.

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3.5 Calibration error
The respective errors or states are displayed in bits (currently bits 1-3) of an IPOS variable (bit 0 is
hidden). The following table shows the different combinations of possible error numbers.
Calibration Description
error
2 Error during travel in positive direction,
the tolerance of 4,096 +/- 20Inc was
exceeded
4 Error during travel in negative direction,
the tolerance of 4,096 +/- 20Inc was
exceeded
6 Tolerance exceeded in both directions
8 Difference between start and final
position has exceeded tolerance of
20Inc
10 Difference between start and final
position as well as travel in positive
direction have exceeded tolerance of
20Inc
12 Difference between start and final
position as well as travel in negative
direction have exceeded tolerance of
20Inc
14 Difference between start and final
position as well as travel in positive and
negative direction have exceeded
tolerance of 20Inc
Possible causes
- Excessive friction, you may have to
increase the measuring current (pay
attention to the motor rated current since
power supply to motor is applied for an
extended period of time)
- Perform calibration without load (remove
gear unit, if possible)
- Is the motor partially blocked (e.g. single
sided)?
- Possible vibration of rotor
In addition:
- Possibly no pulses or incorrect direction
Æ Check encoder connection, a rotation of
the rotor must correspond to 4,096Inc and
a rotation in clockwise direction (viewed on
motor shaft) must increase position; motor
phases (U, V, W) reversed?
- Possibly too many or too few pulses Æ
Motor startup with incorrect number of
pole pairs or motor blocked; if brake
exists, is it released?
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4 Startup of the speed controller
In a final step, you can set the speed controller after installation of the motor in the application.

You can measure the load mass moment of inertia with the “Testing” button. For an accurate
measurement, move the motor through a wide speed range (motor and regenerative).
You can also measure the motor moment of inertia indirectly. Set the “Motor” edit field to 0 and
move the motor without load. The result in the “Load” edit field is the same as for the motor.

Click “Testing” and accept Set value to 0, to measure

the value as the motor the motor’s mass moment
moment of inertia after of inertia
measurement

Click “Next” to get the calculated controller parameters that you may still alter.

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Startup is complete after download. Remember to adjust the maximum current on the first page, if
necessary.

SEW-EURODRIVE GmbH & Co KG assumes

no liability for the operation of
non-SEW synchronous motors with
MOVIDRIVE®

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